How to add a second air feed to your s40 airbox

[Evil Edna]

Righty ho chappies...Here goes.

This was all done in about 45 mins...so it's a quick jobby!

Click the links to see the pics!

STAGE 1

Preliminaries and removal of airbox

Start off by going to your local motor shop. Buy some alu ducting ( bought about a meter of it), A filter reducer and a filter adapter. Available from Race X, ask if you want the part numbers.

http://i11.photobucket.com/albums/a1...ir%20box/1.jpg

Now it's time to remove the airbox.
Firstly, undo the two bolts which hold in the fuse box. Remove the bolts and push the fuse box somewhere out the way...making sure you dont rip any wiring.

On the s40, there are 2 bolts which hold the air box in, one is located on the passenger wing (inside, obviously) and the other is behind the air recirculation box (basically,m between the edge of the fuse box and the back of the air box. All the bolts are 10mm.

Once you've done this, you'll see the box has a push-fit fitting next to the battery. Pull this up and out. With a little messing, it comes out.

http://i11.photobucket.com/albums/a1...ir%20box/2.jpg

STAGE 2

Removing the recirculation box.

Depending on the size and shape of the ducting you have, will depend on where you decide to put the intake. Stage 2 was suitable for me, you may want to put the intake on the face closest to the battery. Decide where first!

This is a seperate box on the back of the main air box which clips off.

http://i11.photobucket.com/albums/a1...ir%20box/3.jpg

You'll see two plastic clips moulded into the recirculation box that clip on to the main airbox, give it a push down and you'll soon have it off. I accidently Broke one of mine as it came off, but there wont be much use for it now anyway.

http://i11.photobucket.com/albums/a1...ir%20box/4.jpg

You'll also notice the recirculation box has a pipe which goes into the main airbox. Once the clips have come off the recirculation box, twist and pull! the pipe may be a bit tough to get out, but it comes out eventually.

STAGE 3

Marking up and boreing out the air box.

After the recircualtion box has been removed, Take the filter adapter and place it onto the side of the box, where the recirculation pipe went into the main box. use a pen and mark round the inside circle.

The best way to bore the hole out would be to use a hole cutting tool..quite obviously. But as my dad decided to steal my tools for the day, i ended up using a drill and a stanley knife! Basically use anything, as long as you stay in the circle, wear the appropriate protection and take your time, you shouldn't have any problems!

http://i11.photobucket.com/albums/a1...ir%20box/5.jpg

STAGE 4

Fitting the filter adapter and reducer.

Once the hole has been bored out, place the filter adapter over the hole and make small markings using a pen for the screws to go, Then drill pilot holes. Make sure the holes aren't too big, as you'll want to make usre the screws take to the plastic of the box.

Once the holes are done, screw the adapter on!

http://i11.photobucket.com/albums/a1...ir%20box/6.jpg

There are two options now, you can either take the screws out and use nuts and bolts, or just cut the end of the screws off, making sure there is enough thread left on so the screws stay in.

http://i11.photobucket.com/albums/a1...ir%20box/7.jpg

Then put the filter reducer on!

http://i11.photobucket.com/albums/a1...ir%20box/8.jpg

STAGE 5

Ducting..


Before you start with this section, give the box a quick vac, as there will be lots of pissy bits of plastic inside.

You also may want to consider sealing the ducting with e.g silicone to keep secure ( read on, you'll understand..)

Two options now, you can either:

A) Route the ducting first and connect up to the box after

B) Connect the ducting to the box and fit all at once (recommended)

I went with B as i found (A) to ba a pain in the arse. It all depends on where you want the ducting to go.

To conncet the ducting, simply push it through the reducer so it fits snug. Make sure there is enough of the ducting inside the box to keep it in position while you mess around routing it.

I decided to go for the easyiest route for the ducting...Straight down. Some people may argue with this as "it might pick up water"..But i had exactly the same route as i did on my old corsa, and it never picked up water. It has too far to travel basically, so i guess its optional.

Make sure when routing straight down, the ducting isn't blocking anything, especially the clutch cylinder-type thing (oh...how technical!)
Once the ducting's in place, secure it to the undertray by whatever means you want to..I personally cut a hole out and pushed the ducting though..seems to be nice and secure, and doesn't rattle.

http://i11.photobucket.com/albums/a1...ir%20box/9.jpg

STAGE 6

Refitting.

Basically stage 1 backwards, Just make sure everythings secure, doesn't rattle..and nothings bodged!

http://i11.photobucket.com/albums/a1...r%20box/10.jpg

Hey presto! you've got a second air feed! Now stick an itg/pipercross/K & N and listen to it roar...and give a little more performance!

http://i11.photobucket.com/albums/a1...r%20box/11.jpg

Evna.

[Vikingxl]

Nice write up well done mate!

[T5frankie]

Righty ho chappies...Here goes.

This was all done in about 45 mins...so it's a quick jobby!

Click the links to see the pics!

STAGE 1

Preliminaries and removal of airbox

Start off by going to your local motor shop. Buy some alu ducting ( bought about a meter of it), A filter reducer and a filter adapter. Available from Race X, ask if you want the part numbers.

http://i11.photobucket.com/albums/a1...ir%20box/1.jpg

Now it's time to remove the airbox.
Firstly, undo the two bolts which hold in the fuse box. Remove the bolts and push the fuse box somewhere out the way...making sure you dont rip any wiring.

On the s40, there are 2 bolts which hold the air box in, one is located on the passenger wing (inside, obviously) and the other is behind the air recirculation box (basically,m between the edge of the fuse box and the back of the air box. All the bolts are 10mm.

Once you've done this, you'll see the box has a push-fit fitting next to the battery. Pull this up and out. With a little messing, it comes out.

http://i11.photobucket.com/albums/a1...ir%20box/2.jpg

STAGE 2

Removing the recirculation box.

Depending on the size and shape of the ducting you have, will depend on where you decide to put the intake. Stage 2 was suitable for me, you may want to put the intake on the face closest to the battery. Decide where first!

This is a seperate box on the back of the main air box which clips off.

http://i11.photobucket.com/albums/a1...ir%20box/3.jpg

You'll see two plastic clips moulded into the recirculation box that clip on to the main airbox, give it a push down and you'll soon have it off. I accidently Broke one of mine as it came off, but there wont be much use for it now anyway.

http://i11.photobucket.com/albums/a1...ir%20box/4.jpg

You'll also notice the recirculation box has a pipe which goes into the main airbox. Once the clips have come off the recirculation box, twist and pull! the pipe may be a bit tough to get out, but it comes out eventually.

STAGE 3

Marking up and boreing out the air box.

After the recircualtion box has been removed, Take the filter adapter and place it onto the side of the box, where the recirculation pipe went into the main box. use a pen and mark round the inside circle.

The best way to bore the hole out would be to use a hole cutting tool..quite obviously. But as my dad decided to steal my tools for the day, i ended up using a drill and a stanley knife! Basically use anything, as long as you stay in the circle, wear the appropriate protection and take your time, you shouldn't have any problems!

http://i11.photobucket.com/albums/a1...ir%20box/5.jpg

STAGE 4

Fitting the filter adapter and reducer.

Once the hole has been bored out, place the filter adapter over the hole and make small markings using a pen for the screws to go, Then drill pilot holes. Make sure the holes aren't too big, as you'll want to make usre the screws take to the plastic of the box.

Once the holes are done, screw the adapter on!

http://i11.photobucket.com/albums/a1...ir%20box/6.jpg

There are two options now, you can either take the screws out and use nuts and bolts, or just cut the end of the screws off, making sure there is enough thread left on so the screws stay in.

http://i11.photobucket.com/albums/a1...ir%20box/7.jpg

Then put the filter reducer on!

http://i11.photobucket.com/albums/a1...ir%20box/8.jpg

STAGE 5

Ducting..


Before you start with this section, give the box a quick vac, as there will be lots of pissy bits of plastic inside.

You also may want to consider sealing the ducting with e.g silicone to keep secure ( read on, you'll understand..)

Two options now, you can either:

A) Route the ducting first and connect up to the box after

B) Connect the ducting to the box and fit all at once (recommended)

I went with B as i found (A) to ba a pain in the arse. It all depends on where you want the ducting to go.

To conncet the ducting, simply push it through the reducer so it fits snug. Make sure there is enough of the ducting inside the box to keep it in position while you mess around routing it.

I decided to go for the easyiest route for the ducting...Straight down. Some people may argue with this as "it might pick up water"..But i had exactly the same route as i did on my old corsa, and it never picked up water. It has too far to travel basically, so i guess its optional.

Make sure when routing straight down, the ducting isn't blocking anything, especially the clutch cylinder-type thing (oh...how technical!)
Once the ducting's in place, secure it to the undertray by whatever means you want to..I personally cut a hole out and pushed the ducting though..seems to be nice and secure, and doesn't rattle.

http://i11.photobucket.com/albums/a1...ir%20box/9.jpg

STAGE 6

Refitting.

Basically stage 1 backwards, Just make sure everythings secure, doesn't rattle..and nothings bodged!

http://i11.photobucket.com/albums/a1...r%20box/10.jpg

Hey presto! you've got a second air feed! Now stick an itg/pipercross/K & N and listen to it roar...and give a little more performance!

http://i11.photobucket.com/albums/a1...r%20box/11.jpg

Evna.

THANKS FOR THE IDEA.